Automatic repacking and accumulation system

ABSTRACT

A distinctive method and apparatus for accumulating selected articles can include an inputting of a plurality of individual articles ( 28 ) from an article supply source ( 26 ). Each article can have at least a first major facing surface ( 30 ), a first article dimension ( 32 ) extending along a first article direction, a second article dimension ( 34 ) extending along a second article direction which differs from the first article direction, and an article edge region ( 36 ). Each article can be directed to a first conveyor ( 50 ), and in a particular aspect, the first article dimension of each article can be aligned along a selected machine-direction ( 22 ). Another aspect can include an identifying of an article-set ( 70 ) which contains a selected, predetermined number of the articles. Further aspects can include a forming of at least one article-set which contains the selected number articles arranged in a stack or other arrangement suitable for packaging; and a moving of the article-set into a package. In additional aspects, the inputting of the articles can include a metering of the articles, and the inputting of the articles can include a dispensing of the articles ( 28 ) with a rotating, metering drum ( 40 ). In still further aspects, the inputting of the articles can include a delivering of the articles onto a guide surface, and the delivering of the articles can include a laying of the articles onto a directing slide ( 42 ), which may be inclined.

FIELD OF THE INVENTION

The invention generally relates to an apparatus and method forprocessing individual, loose articles. More particularly the inventionrelates to an apparatus and method for efficiently arranging loosearticles into a configuration that can be readily introduced into aselected packaging system.

BACKGROUND OF THE INVENTION

Conventional systems for automatically packaging articles produced on amanufacturing line are well known. Individual articles received from themanufacturing line have been counted and arranged into one or morestacks by employing conventional devices. Additionally, conventionaldevices have been employed to insert the stacks into pre-selectedpackages, such as cartons or bags.

During the conventional stacking and packaging operations, however,individual articles have often become dislodged or otherwise divertedfrom the ordinary manufacturing and packaging operations. While theresulting loose articles have been commercially acceptable, it has beendifficult to reintroduce the articles into the ongoing manufacturingprocesses. Typically, the individual loose articles have been gathered,rearranged and stacked by hand. The resulting stacks have then beenmanually introduced back into the packaging operation.

The manual sorting and stacking operations, however, have beenexcessively inefficient and costly. As a result, there has been acontinuing need for an automated system that can more efficientlyrearrange, sort and reorient the individual loose articles. There hasalso been a continuing need for an automated system that can moreefficiently stack or otherwise arrange the articles, and insert theresulting article stacks or other arrangements into desired packages.

BRIEF DESCRIPTION OF THE INVENTION

The present invention can provide a method and apparatus foraccumulating articles. A method aspect can include an inputting of aplurality of individual articles from an article supply source. Eacharticle can be directed to a first conveyor, and in a particular aspect,a first article dimension of each article can be aligned along aselected machine-direction. Another aspect can include an identifying ofan article-set which contains a selected, predetermined number of thearticles. Further aspects can include a forming of at least onearticle-set which contains the selected number articles arranged in aconfiguration suitable for packaging, and a moving of the article-setinto a package. In additional aspects, the inputting of the articles caninclude a metering of the articles, and the inputting of the articlescan include a dispensing of the articles with a rotating, metering drum.In still further aspects, the inputting of the articles can include adelivering of the articles onto a guide surface, and the delivering ofsaid articles can include a laying of the articles onto an inclineddirecting slide.

An apparatus aspect can include an input mechanism which delivers aplurality of individual articles from an article supply source into aguide mechanism. The guide mechanism can direct the articles to a firstconveyor, and in a particular feature, an alignment mechanism can orienta first article dimension of each article along a selectedmachine-direction. In other features, a sorting mechanism can form atleast one article-set that contains a selected number of the articlesarranged in a configuration suitable for packaging, and a transfermechanism can move the article-set into a package.

In its various aspects and features, the present invention can moreeffectively and more efficiently provide a processing system capable ofconverting individual, loose articles into a configuration that can beefficiently and automatically recovered and inserted into a selectedpackaging system. The method and apparatus of the invention caneffectively accumulate, meter, orient, arrange, and transfer therecovered articles into the packaging system. The technique of theinvention is readily placed at a desired location, and is readilyadaptable to handle grade changes and different types of articles.Additionally, the method and apparatus of the invention can be highlyreliable and can operate at desired, high speeds.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention will be more fully understood and further advantages willbecome apparent when reference is made to the following detaileddescription of the invention and to the drawings in which:

FIG. 1 shows a perspective view of a representative article that can beprocessed by the method and apparatus of the invention.

FIG. 1A shows a perspective view of a representative article-set thatcan be produced and processed by the method and apparatus of theinvention.

FIG. 1B shows a perspective view of a representative grouping ofarticle-sets which form a representative plurality of article-sets thatcan be produced and processed by the method and apparatus of theinvention.

FIG. 2 shows a schematic view of a representative method and apparatusof the invention.

FIG. 3 representatively shows a schematic, perspective view of ametering section that can be employed with the present invention.

FIG. 3A representatively shows a schematic end view of a meteringsection that can be employed with the present invention.

FIG. 4 representatively shows a schematic, perspective view of themetering section and a directing or guide system that can be employed inthe method and apparatus of the invention.

FIG. 4A representatively shows a schematic, partially cut-away, sideview of the metering section and directing or guide section that can beemployed in the method and apparatus of the invention.

FIG. 5 representatively shows a schematic, perspective view of analignment section that can be employed with the present invention.

FIG. 5A representatively shows an enlarged, schematic, perspective viewof an alignment section that can be employed with the present invention.

FIG. 6 representatively shows a perspective view of an alignment sectionand sequencing section that can be employed with the present invention.

FIG. 6A representatively shows an enlarged, perspective view of asequencing section that employs a system of lobed-cams.

FIG. 7 representatively shows a schematic, perspective view of anorienting section that employs an indexing carriage.

FIG. 8 representatively shows a schematic, perspective view of analternative orienting section that employs an indexing carriage providedby an indexing wheel.

FIG. 9 representatively shows a schematic, perspective view of astacking section that can receive articles from an orienting section.

FIG. 9A representatively shows another schematic, perspective view ofthe stacking section that can receive articles from the orientingsection.

FIG. 10 representatively shows a schematic, perspective view of aloading section that can receive articles from the stacking section.

FIG. 10A representatively shows another schematic, perspective view ofthe loading section that can receive articles from the stacking section

FIG. 11 representatively shows an enlarged, perspective view of theloading section that can be employed with the method and apparatus ofthe invention.

FIG. 11A representatively shows a perspective view of a loading sectionwhere a predetermined article-set has been positioned on a stagingmechanism.

FIG. 11B representatively shows a perspective view of a loading sectionwhere a predetermined plurality of article-sets have been positioned ina loading mechanism.

FIG. 11C representatively shows a perspective view of a loading sectionwhere a predetermined plurality of article-sets are being moved into aselected package.

DETAILED DESCRIPTION OF THE INVENTION

It should be noted that, when employed in the present disclosure, theterms “comprises”, “comprising” and other derivatives from the root term“comprise” are intended to be open-ended terms that specify the presenceof any stated features, elements, integers, steps, or components, andare not intended to preclude the presence or addition of one or moreother features, elements, integers, steps, components, or groupsthereof.

With reference to FIGS. 2 and 5A, the process and apparatus 20 of theinvention can have a lengthwise, machine-direction 22 which extendslongitudinally, a lateral cross-direction 24 which extends transversely,and an appointed z-direction. For the purposes of the presentdisclosure, the machine-direction 22 is the direction along which aparticular component or material is transported length-wise along andthrough a particular, local position of the apparatus and method. Thecross-direction 26 lies generally parallel to the local horizontal, andis aligned perpendicular to the local machine-direction 22. Thez-direction is aligned substantially perpendicular to both themachine-direction 22 and the cross-direction 24, and extends generallyalong a depth-wise, thickness dimension.

As illustrated, the present invention can provide a distinctivetechnique and system for accumulating selected articles. With referenceto FIGS. 1 and 2, a method aspect can comprise an inputting of aplurality of individual articles 28 from an article supply source 26.Each article can have at least a first major facing surface 30, a firstarticle dimension 32 extending along a first article direction, a secondarticle dimension 34 extending along a second article direction whichdiffers from the first article direction, and an article edge region 36.Each article can be directed to a first conveyor 50, and in a particularaspect, the first article dimension of each article can be aligned alonga selected machine-direction 22. Another aspect can include anidentifying of an article-set 70 which contains a selected,predetermined number of the articles. Further aspects can include aforming of at least one article-set which contains the selected numberarticles arranged in a stack or other configuration that is suitable forpackaging, and a moving of the article-set into a package. In additionalaspects, the inputting of the articles can include a metering of thearticles, and the inputting of the articles can include a dispensing ofthe articles 28 with a rotating, metering drum 40. In still furtheraspects, the inputting of the articles can include a delivering of thearticles onto a guide surface, and the delivering of the articles caninclude a laying of the articles onto a directing slide 42, which may beinclined.

An apparatus aspect can comprise an input mechanism which delivers aplurality of individual articles 28 from an article supply source 26.Each article can have at least a first major facing surface 30, a firstarticle dimension 32 extending along a first article direction, and anarticle edge region 36. A guide mechanism can direct the articles 28 toa first conveyor 50, and an alignment mechanism can orient the firstarticle dimension of each article 28 along a selected machine-direction22. A sorting mechanism can form at least one article-set 70 thatcontains a selected number of the articles 28 arranged in aconfiguration suitable for packaging, and a transfer mechanism can movethe article-set 70 into a suitable, conventional package. Another aspectcan include a processing mechanism which operatively groups a pluralityof article-sets 70, and the article-sets can be moved into anappropriate package.

In another aspect, a method 20 for accumulating articles 28 can includea dispensing of the articles with a rotating, metering drum 40 formovement to a first conveyor 50. The metering drum 40 has an entry end86 and an exit end 88, and in a particular aspect, the metering drum 40can be configured such that a rotation of the metering drum overcomes astatic friction which would inhibit a movement of the articles 28downstream through the metering drum.

Another apparatus aspect can include a rotatable, metering drum 40 whichcan dispense the articles 28 for movement to a first conveyor 50. Themetering drum 40 has an entry end 86 and an exit end 88, and in aparticular aspect, the metering drum 40 can be configured such that arotation of the metering drum overcomes a static friction which wouldinhibit a movement of the articles 28 downstream through the meteringdrum 40.

In another feature the metering drum 40 can include at least one lugmember 90 which is positioned and attached inside the metering drum atthe exit end 88 of the metering drum. In further features, a ramp member43 can be configured to extend an operative distance into the volume ofthe metering drum, and can be spaced away from an inside wall surface ofthe metering drum by a selected offset distance.

In a further aspect, a method for accumulating articles 28 includesinputting a plurality of individual articles to deliver the articlesfrom an article supply source 26 onto an inclined slide 42 having aguide surface. In particular features, the articles can be regulatedwith a guide member 44, and directed to a first conveyor 50.

A further apparatus aspect can include an article supply source 26. Inparticular aspects, an inclined slide 42 has a guide surface and can beconfigured to receive articles 28 delivered from the article supplysource 26. In further features, a guide member 44 can be configured toregulate the articles delivered to the inclined slide 42, and thearticles can be delivered to a first conveyor 50.

Additional features can include guide member 44 which is formed toincorporate a generally S-shaped, funnel curve; and an article stopplate mechanism 48 which can direct the articles to engage an edgeregion 36 of each article 28 on the first conveyor 50, and provide astanding, on-edge arrangement of each article. Still another feature caninclude a transfer guide ramp mechanism 46 which can operatively providea substantially smooth contour between the inclined slide 42 and saidfirst conveyor 50.

An additional method aspect for accumulating articles 28 can includeconveying a plurality of individual articles with a stacking conveyor96. In particular aspects, the stacking conveyor can have a plurality ofholding members 112 that project away from an article-side surface ofthe stacking conveyor 96, and the stacking conveyor can be arranged withan elbow configuration to substantially avoid an undesired encircling orsurrounding of a substantially fixed portion of cooperating downstreamequipment.

An additional apparatus aspect can include a stacking conveyor 96 formoving a plurality of individual articles 28. The stacking conveyor 96can be arranged with an elbow configuration which substantially avoidsan undesired encircling or surrounding of a substantially fixed portionof cooperating, downstream equipment. Additionally, the stackingconveyor can have a plurality of holding members 112 that project awayfrom an article-side surface of the stacking conveyor 96.

In another feature, the method and apparatus can include a turningmechanism which forms the elbow configuration. The turning mechanism caninclude a first turn roller system 128 and a second turn roller system130 (e.g. FIG. 9). The first turn roller system 128 can be configured tooperatively engage at least an appointed bottom portion of the stackingconveyor 96, and the second turn roller system 130 can be configured tooperatively engage at least a portion of an appointed article-side ofthe stacking conveyor.

A further feature can include a transfer system 98 which can cooperatewith a vacuum system 100 to load the articles 28 into downstreampackaging equipment. The vacuum system 100 can desirably be configuredto vacuum-hold the articles 28 in a substantially fully-suspendedposition. Still another aspect can include a storage buffer mechanism104 which provides an area upon which to stage at least one article-set70 (e.g. FIG. 10).

In still another aspect, a method for selectively orienting an article28 can include a selective indexing of a movable carriage 94 (e.g. FIG.7) between a first carriage position and at least a second carriageposition, thereby providing a selected face-alignment of a datum surface74 of the article. In particular features, the first carriage positioncan be configured to provide for a first, twist displacement of thearticle, and the second carriage position can be configured to providefor a second, twist displacement of the article, with the second twistdisplacement directionally opposite to the first twist displacement.

Still another apparatus aspect for selectively orienting an article 28can include a movable carriage 94 which can index between a firstcarriage position and at least a second carriage position, therebyproviding a selected face-alignment of a datum surface of said article.The first carriage position can be configured to provide for a first,twist displacement; and the second carriage position can be configuredto provide for a second, twist displacement that is directionallyopposite to said first twist displacement. In a particular feature, themovable carriage can include an indexing wheel 120 (e.g. FIG. 8). Inanother feature, at least a first set of twist-belts 66 can be connectedto the carriage 94. In a desired arrangement, the first set oftwist-belts 66 can be connected to the indexing wheel 120.

In its various aspects and features, the present invention can moreeffectively and more efficiently provide a processing system that canconvert individual, loose articles into a configuration that can beefficiently and automatically recovered and inserted into a selectedpackaging system. The method and apparatus of the invention canefficiently and automatically meter, align, arrange and transfer therecovered articles into the appointed packaging system. In an optionalfeature, the system of the invention can also be configured toselectively twist or otherwise orientate the recovered articles into adesired arrangement. A further feature of the method and apparatus canprovide an ability to automatically detect an entry point in the finalpackaging machinery, and transfer a packaging-set of the articles intothe packaging machinery, with substantially no manual intervention by anoperator.

The technique of the invention can be readily and selectively positionedat a desired location within a manufacturing line, and can be readilyadapted to handle grade changes and different types of articles. As aresult, the technique of the invention can provide a highly reliable,high-speed method and apparatus that can efficiently accumulateindividual articles for packaging.

With reference to FIGS. 1 through 1B, each article can have at least afirst major facing surface 30, a first article dimension 32 extendingalong a first article direction, a second article dimension 34 extendingalong a second article direction which differs from the first articledirection, and an article edge region 36. As representatively shown, thefirst article dimension 32 can be relatively larger than the secondarticle dimension 34. The article can additionally have at least asecond major facing surface 30 a which is positioned in an opposedrelation to the first major surface 30, and an article thicknessdimension 35. In a particular arrangement, the article can include apersonal care article. In another arrangement, the article can comprisea packet or pouch which contains a personal care absorbent article. Inthe various arrangements, the personal care absorbent article can, forexample, be a feminine care article, incontinence article, child carearticle, infant care article or the like. The feminine care article canbe a sanitary napkin, a menstrual pad, a panty liner, an interlabialdevice or the like, as well as a combination thereof.

Proper control of the flow of articles can be particularly important. Ifa large number of articles are in close proximity to one another andquickly delivered into an accumulation and repacking system, the systemcan jam, or provide an excessive amount of “dead time” during which noproduct is being delivered. The method and apparatus can be configuredto reduce an undesired clumping and jamming of multiple articles withinthe process line, and can reduce an accompanying disruption of theaccumulation system. In a particular aspect, the system of the inventioncan provide a substantially single (one-at-a-time) article feed. Thesystem can automatically break down a large quantity of loose articlesto substantially eliminate the need for manually feeding by an operator.

With reference to FIG. 2, the accumulation process and system caninclude a metering section 25, a guide section 27, an alignment section29 and a loading section 33. Additionally, the method and apparatus mayinclude an orienting section 31.

The metering section can be configured to provide an individual,substantially one-at-a-time pad feeding into the accumulation method andapparatus of the invention. Any operative metering device, such as a anoscillating hopper with a narrow exit orifice, a multistage conveyingsystem, a popcorn apparatus with take-away top mounted vacuum conveyoror the like, can be employed, as well as combinations thereof. Withreference to FIGS. 2 through 5, the representatively shown arrangementof the metering device can include a rotatable metering drum 40. Inanother aspect, the metering device can include a feeder hopper 26. Thehopper can provide an operative supply of individual articles 28, andcan be configured to operatively control a flow of articles from thehopper. For example, the hopper can be a conventional gravity-fedhopper, and can include an exit gate 62 (e.g. FIG. 4A) which controls aflow of product into the entry of the metering unit. In a particularfeature, the gate can open and close based on a detected level ofarticles in the metering unit. As representatively shown a actuatingmechanism 80, such as a mechanism which includes a pneumatic cylinder,can be connected to selectively open and close the exit gate 62.

The metering section can, for example, be provided by a mechanism whichincludes the shown, rotatable metering drum. The metering drum 40 can bea hollow cylinder, and can have generally circular openings at eachterminal end. In a particular feature, the metering drum can be mountedat a selected drum tilt angle 84, as measured from the local horizontal(e.g. FIG. 4A). The drum tilt angle can help the articles flow towardthe discharge, exit end of the drum. In a particular aspect, the drumtilt angle can be at least a minimum of about 1 degree (1°). The drumtilt angle can alternatively be at least about 2 degrees, and canoptionally be at least about 3 degrees. In another aspect, the drum tiltangle can be up to about 45 degrees, or more. The drum tilt angle canalternatively be up to about 30 degrees, and can optionally be up toabout 15 degrees to provide improved performance. In still otherarrangements, the drum tilt angle can be not more than about 5 degrees.If the drum tilt angle is too large, there can be an excessive clumpingof articles, an excessive tumbling of the articles and an excessiveoccurrence of downstream jams. If the drum tilt angle is too small thearticles may not reliably exit the metering drum.

As representatively shown, an entry end 86 of the metering drum can bemounted relatively higher than an exit end 88 of the drum. Each end ofthe drum 84 can be selectively, partially blocked by a separate,stationary plate member. Additionally, each plate member can coverapproximately ½ to approximately ⅔ of the lower, bottom portion of thedrum cylinder. For example, a first stationary plate member 81 can belocated upstream of the entry end 86 of the metering drum, andpositioned operatively adjacent the entry end of the drum. In a desiredarrangement, an approximate, bottom two-thirds of an entry end openingof the drum 86 can be operatively blocked by the first stationary plate81, leaving an approximate, top one-third of the drum, entry end openingsubstantially unobstructed. Accordingly, the first stationary plate canhold articles in the metering drum while allowing the metering drum torotate adjacent the stationary plate.

A second stationary plate member 82 can be located operatively adjacentthe exit end 88 of the drum, and positioned relatively downstream fromthe metering drum. In a desired arrangement, the second stationary plate82 can operatively cover or otherwise block an approximate, bottom halfof an exit end opening of the drum. As a result, the second stationaryplate can help prevent articles from falling out from the bottom-side ofthe drum while allowing the drum to rotate past the stationary plate.

On the entry end 86 of the drum 40, an entry-slide 38 can becooperatively associated with and positioned at a top region of thefirst stationary plate at the entry end of the drum. As representativelyshown, for example, the entry-slide can be attached or otherwise joinedto the top region of the first stationary plate at the entry end of thedrum. The entry-slide can funnel or otherwise direct the individualloose article into the drum 40 from the supply/feed hopper, and caninclude side rails to help hold the articles on the entry-slide. As aresult, the system can maintain a substantially consistent level ofproduct can be maintained, and can allow for substantially continuousoperation of the accumulation system.

The metering drum 40 can be operatively mounted on external bearings 41which provide for a desired drum rotation, while maintaining asubstantially fixed position of a drum axis of rotation. The drum can bedriven externally, and is configured to provide a substantiallyunobstructed flow of articles through the drum. The drum configurationcan generate a proportional relationship between the metering drum'srotational velocity and the article feed rate. In other words, thefaster the drum rotates, the faster flow of articles out of the drum.The article feed rate can also be adjusted by altering the drum tiltangle 84. The drum can be turned at any operative rotational speed. In aparticular feature, the rotation speed can, for example, be at least aminimum of about 5 revolutions per minute (rpm). In another feature, thedrum speed can be up to about 40 revolutions per minute to providedesired performance.

The metering drum 40 can have any operative size or configuration, andcan be constructed of any operative material. As representatively shown,for example, the drum can be constructed of a hardened polymer orstainless steel. Additionally the drum may have a diameter of about 46cm, and an axial length of about 102 cm.

In a particular feature, at least one lug type member 90, such asprovided by the representatively shown lug block, can be positioned andattached to a region inside the metering drum at the drum exit end 88.In a desired arrangement, the drum can include a lug system having aplurality of lug members or blocks. The radially-inward extending height91 of each lug member (as measured from its corresponding inside surfaceof the metering drum) can be sized to operatively engage and isolate atleast one individual metered article. In a desired aspect, the lugheight 91 can be sized to be approximately equal to the thickness 35 ofthe articles being processed. Additionally, the longitudinal, axiallength 89 of each lug member can be approximately equal to a majorlength dimension of the article. For example, the axial lug length 89 ofeach lug member can be approximately equal to the first length dimension32 of the article 28.

As representatively shown, two drum lug members 90 may be spaced about180 degrees apart along an inside, circumferential surface of the drum.Each lug can be arrayed and mounted along a drum region at thedischarge, exit end 88 of the drum, and can be positioned substantiallyflush with the exit end of the drum. During rotation, each lug can catchor otherwise engage an individual metered article, and can move themetered article in association with the rotating drum wall. Asrepresentatively shown the lug member can hold the article adjacent toor against the inner wall surface of the metering drum. Other articles,which are not operatively engaged by the lug, can effectively fall awayfrom the engaged article. The remaining engaged article can then becarried by its associated lug member 90, and delivered to a positionhaving a height above the top of the second stationary plate member 82.The metered article can then fall or otherwise be deposited from the lugmember onto an exit ramp member 43. As a result, a regular or irregularseries of articles can be discharged out from the exit end 88 of thedrum 40, and moved away from the metering drum.

In an alternative configuration, a vacuum commutation system may beemployed to transport the articles to the discharge, exit end 88 of themetering drum. Additionally, the vacuum commutator may replace the lugs.The vacuum commutation system may allow for a more aggressive spacingand pickup.

In a particular arrangement, an exit ramp plate or other ramp member 43can be operatively positioned to extend along an exit region at the exitend 88 of the metering drum 40, and can be configured with an operativeramp angle. The ramp member can be configured to extend an operativedistance into the volume of the metering drum 40, and can be generallyradially, spaced away from the inside, cylindrical wall surface of themetering drum by a selected spacing offset distance. As a result of theoffset distance, the drum lugs 90 and any entrained article can movepast the exit ramp 43 without excessively contacting the drum exit ramp43. Desirably, the drum lugs and entrained article can substantiallyavoid contact with the exit ramp 43. In a particular feature, the rampspacing distance can be approximately 1.5 times the thickness dimension35 of a metered article. Once the entrained article has been carriedpast the level of the exit ramp 43, the article can fall or otherwise bemoved off of the cooperating lug member 90 and onto the exit ramp 43.

The ramp member can be configured to catch articles that exit from themetering drum 40, and can help transfer and deposit the articles into aselected guide system. The guide system can help to selectively positionand arrange the articles, and can help transport the articles to thefirst, take-away conveyor 50. In a particular aspect, the guide systemcan include a directing slide 42, and the ramp member 43 can beoperatively associated with the directing slide. As representativelyshown, the ramp member 43 can be operatively connected and joined to thedirecting slide.

During operation, the supply hopper 26 can operatively keep the meteringdrum loaded by feeding articles into the entry end 86 of the meteringdrum, as required. Individual articles 28 can be loaded into the entryend 86 of the metering drum 40, and can gradually work their way to theexit end as the drum rotates. The metering drum is configured such thata rotation of the drum helps overcome the static friction which wouldotherwise inhibit the desired movement of articles downstream throughthe drum. When the product reaches the exit end 88 of the drum, themetering lugs (or vacuum commutation system) can catch an article andbring it to the discharge, exit end 88 of the rotating drum, and candischarge the article onto the exit, ramp plate. As a result, themetering drum can rotate and deliver pouches approximately one-at-a-timeonto the directing slide 42. The metering operation and system cansubstantially prevent an excessively large group of multiple productsfrom being fed, all at once, onto the directing slide 42. This canreduce an undesired clogging of the input system, and improve thethroughput capability of the overall operation and system.

Various sensors and controls can be employed to regulate the operationof one or more sections of the method and apparatus of the invention. Inthe various arrangements or aspects of the invention, any operativesensor device may be employed, and a suitable sensor may include aphoto-eye detector, an electromagnetic detector, a sonic detector, aferrous proximity detector, a luminescence detector, a vision systemdetector or the like, as well as combinations thereof.

Conventional sensors and controls can be employed to regulate thearticle input system. In the example of the representatively shownconfiguration, an array or other system of hopper sensors can beemployed to detect and regulate the level of articles in the feed hopper26. The hopper sensors can include a first, high-level sensor (e.g. suchas provided by a first arrangement of at least one photo-eye) and asecond, low-level sensor (e.g. such as provided by a second arrangementof at least one photo-eye). The first level sensor can include a firstphoto-eye located approximately three-quarters of the way up from thebottom of the hopper 26, and arranged to look from corner to corneralong a first diagonal. The first level sensor can also include a first,complementary photo-eye located approximately three-quarters of the wayup from the bottom of the hopper 26, and arranged to look from corner tocorner along a second diagonal. The first level sensor can detect thelevel of the feed hopper to control an automatic feed of loose articlesinto the hopper. The first level sensor can also be used to help detectjam conditions.

The second level sensor can include a second photo-eye can be locatedoperatively proximate a bottom discharge area of the hopper 26, and canbe arranged to look across the volume of the hopper. The second sensorcan be configured to detect when the hopper is empty or nearly empty,and can be configured to help to allow the method and apparatus to gointo a “sleep” mode until more articles are supplied to the hopper.

A control mechanism, such as provided by a solenoid valve and anassociated activation device, can be operatively located to control theopening and/or closing of the exit gate at the bottom of the hopper 26.Conventional activation devices are well known in the art, and anyoperative activation device may be employed. The control mechanism canbe configured to maintain a sufficient quantity of articles in themetering drum, and can be configured to initiate when a sensor in themetering drum has detected a low-level condition.

It should be readily appreciated that in the various systems andcomponents of the present disclosure, any operative activation devicemay be employed. Such activation devices and/or drive mechanisms mayinclude fluidic cylinders, fluidic servos, pneumatic servos,electromagnetic servos, stepper motors, regular motors or the like, aswell as combinations thereof. For example, the activation device can beprovided by an array of pneumatic cylinders.

A gating switch device, such as provided by a proximity switch, can beconfigured to detect an open and/or closed condition of the hopper exitgate 62, and can be operatively located on the activation device thatcontrols the opening and closing of the hopper exit gate. The switch canalso help to verify that the gate has appropriately opened or closed, orto provide other desired feedback information.

A metering drum sensor, such as provided by a photo-eye, can beconfigured to detect a low-level condition in the metering drum 40 orother metering device. The drum sensor can, for example, be arranged tolook through the metering drum and observe between the stationary platesat the entry and exit ends of the metering drum. The drum sensor cancheck the level of articles present in the metering drum, and can beused to trigger an additional flow of articles into the metering drum.

A complementary drum sensor, such as provided by a complementaryphoto-eye, can be configured to detect a very-low-level condition in themetering drum 40 or other metering device. The complementary drum sensorcan be configured to look through metering drum and observe between thelower, bottom regions of the stationary plates at the entry and exitends of the metering drum. The complementary drum sensor can check for avery low, nearly-out condition of the metering drum, and can helpprovide an additional aspect of metering control.

An operative drive mechanism, such as provided by an electric motor witha variable-speed or fixed-speed drive, can be employed to rotate themetering drum 40. The drive mechanism can be mounted operativelyproximate the metering drum to spin the drum at a desired rotationalspeed. The drive mechanism can help control to regulate a rate at whicharticles are deposited onto the directing slide 42. The variable speedcontrol can help control the speed and reliability of the inputtingsystem, although it is not required for operation.

A speed switch device, such as provided by a mechanism which includes aproximity switch, can be incorporated to select and enable a slow-speedrotation of the metering drum. The speed switch mechanism can be mountedoperatively proximate to an outer surface of the metering drum 40, andcan be configured to be triggered by flag mechanism, such as provided bya metallic flag. The flag can be placed at any operative location on themetering drum, and can help provide an ability to switch to a differentspeed set-point. The different speed set-point can help provide avariable speed profile which may provide additional throughputcapability.

The article guide system or section of the method and apparatus canoperatively rearrange and transfer the articles to the first conveyor50. The guide system can be configured to properly and consistentlyarrange the articles 28 into an article layout position and canselectively arrange the articles for a desired processing by an articlealignment system. With reference to FIGS. 2, 4 and 4A, a particularaspect of the guide system can include an inclined directing slide 42,and the slide can include an associated, article-side, guide surfacewhich contacts or otherwise engages the articles 28. The guide surfacemay be substantially flat or may be curved, as desired. In a particulararrangement, at least a portion of the guide surface can present aconvex, article-facing surface for contacting or otherwise engaging thearticles 28. Moving the articles onto and over the guide surface canoperatively lay or otherwise place each individual article onto a majorfacing surface of the article. In the shown arrangement, for example,the article 28 can have one or more substantially flat and/or curvedfacing surfaces 30, 30 a, and the directing slide 42, in cooperationwith gravity, can operatively cause the article to lay onto one suchfacing surface. The directing slide 42 can be constructed of anymaterial that has an operatively low coefficient of friction whichallows each individual article to lay-down onto a major facing surfaceof the article. For example, the directing slide can be constructed witha polished stainless steel surface to provide long-term rigidity andlong-term durability of the smooth low-friction surface. The directingslide 42 can be mounted at any operative slide angle 92 sloping downwardfrom the drum metering unit 40 (e.g. FIG. 4A). The slide angle can beconfigured large enough to adequately overcome static-friction forces,and small enough to avoid an excessive speed of the articles when thearticles are transferred to the conveyor 50. In a particular feature theslide angle 92 can be at least a minimum of about 30 degrees, asmeasured from the local horizontal. The slide angle can alternatively beat least about 50 degrees, and can optionally be at least about 55degrees to provide improved performance. In other aspects, the slideangle 92 can be up to a maximum of about 85 degrees, or more. The slideangle can alternatively be up to about 70 degrees, and can optionally beup to about 60 degrees to provide improved effectiveness.

The slide angle 92 can be non-constant or substantially constant alongthe movement direction of the articles to provide a desired control ofthe article transfer speed. For example, the slide angle can be greaterat a region of the directing slide that is proximate the metering device(e.g. metering drum 40), and can be relatively smaller at a region ofthe directing slide that is proximate the conveyor 50. In a particulararrangement, the directing slide 42 can be mounted to provide a slideangle of about 50 degrees, at least in the region of the directing slidethat is proximate the drum exit end 88. This angle can provide a goodbalance of the ability to overcome static forces and the ability tocontrol transfer speed. An excessively steep inclination of the slideangle 92 can create more potential for an undesired tumbling of thearticles.

Sidewall members 45 can be connected and configured to help position andmaintain the articles 28 on the article-side surface of the directingslide. Additionally, a guide member 44 can be operatively joined to theguide surface of the directing slide 42, and the guide member can, forexample, include an operative, guide rail or guide fence. The guidemember can be a generally up-standing mechanism, and can be configuredto extend along a curvilinear, serpentine path. In a particular feature,the guide member can be constructed to incorporate and form aneffective, funnel curve. As a result, the guide member 44 can form anoperative funnel shape which can more effectively channel eachindividual article 28 to a selected delivery region onto the firstconveyor 50.

The guide member can present a flat and smooth, low-friction surface tothe articles, and can be configured to follow a generally S-shapeprofile. As representatively shown, the guide member profile can includean initial, slightly tapered drop from the exit end 88 of the meteringdrum 40, and can then include a relatively gentle (larger radius)concave, “inside” curve followed by a relatively aggressive (smallerradius), oppositely bending, convex, “outside” curve which can help tosequence the articles and allow a controlled drop-off into the take-awayconveyor 50. The guide-fence profile can more effectively provide aconsistent guide path for the articles to follow as the articles arebeing repositioned on the slide. The guide fence can also funnel eacharticle to a consistent delivery region for transfer to the firstconveyor 50. In a particular arrangement, the guide member profile,along its “inside” curve, can be configured to have a radius ofcurvature which is about four times the largest length dimension (e.g.four times the length dimension 32) of the transported article. Alongthe “outside” curve of the guide member, the guide member profile can beconfigured to have a radius of curvature which is about 1.5 times thelargest length dimension of the transported article. While the describedarrangement represents a desired, operative configuration, it should beappreciated that a guide member profile having other radius combinationsmay also be employed to operatively provide an effective mechanism andtechnique for transporting the articles 28. The radii of curvatureemployed by the guide member profile should be configured such that thearticles being transported do not stall on the directing slide 42 andmaintain sufficient momentum to pass the discharge end of the directingslide. The selection of the radii of curvature can depend upon thefrictional properties of the article, of the directing slide, of theguide member. The selection of the radius combination can depend uponthe magnitude of the inclination angle 92 of the slide 42. Generallyspeaking, any combination thereof which allows for consistent deliveryof said article to a singular delivery point at the discharge of theslide will allow system operation.

The conveyor 50 can operatively transport the selectively positionedarticle from the directing slide 42 to an article alignment system.Additionally, the first conveyor 50 can be provided by any operativeconveyor mechanism. For example, the conveyor 50 may be provided by aconventional, vacuum take-away conveyor.

The take-away system can include a tapered, transfer guide rampmechanism 46 which can operatively provide a path profile fortransferring articles onto the take-away conveyor 50. In a particularfeature, the guide ramp 46 can provide a substantially smooth contourbetween the slide 42 and the transition point onto the take-awayconveyor 50. The contour can help ensure that the articles are directedimmediately to the take-away conveyor without stalling.

The guide ramp 46 can work in cooperation with an article stop platemechanism 48. The stop plate 48 can provide a surface to catch articlesmoving from the directing slide 42, and can “kick” or otherwise help todirect and arrange the articles onto the first, take-away conveyor 50.The take-away conveyor 50 can operatively “grab” or otherwise activelyengage the articles that enter the first conveyor, and can move thearticles away from the directing slide 42 at high speed. Therepresentatively shown vacuum conveyor configuration can provide for animproved control of the articles at the take-away point at the articleexit from the directing slide 42. The vacuum feature is optional, butthe resulting, positive take-away operation afforded by the vacuumfeature can advantageously help provide a higher system speed.Desirably, a relatively strong vacuum of about 25.4 cm (10 inches) ofmercury can be provided to the vacuum take-away conveyor. The strongvacuum can help provide more repeatable performance, and help make themethod and apparatus more robust and less sensitive to the shape andcontour of the transfer ramp 46.

As representatively shown, the first conveyor 50 can be configured toengage an edge region 36 of each article, and can be configured toprovide a standing, on-edge arrangement of each article. An operativesystem of guide rails 52 can be employed to help maintain the desiredon-edge arrangement of the articles 28. The selected articles 28 may ormay not have first and second article dimensions 32 and 34,respectively, that are substantially equal. Where the first and secondarticle dimensions are unequal, there can be a preference foridentifying a relatively longer first dimension 32 of the article, andoperatively aligning the first dimension 32 along a corresponding localmachine-direction 22 of the method and apparatus.

As representatively shown, the first conveyor 50 can be configured totransport the articles 28 to an operative alignment device or systemwhich can arrange the articles in a desired, consistent shape placement.With reference to FIGS. 2, 5, 5A and 6 an operative alignment mechanismcan process selected articles with a turning system to thereby rotate orotherwise arrange the selected articles to operatively align the articlefirst dimension 32 of the selected articles along the machine-direction22. The processing of the selected articles can include a turning of theselected articles with a turning member. The turning of the article caninclude a direct-contact engagement, or a substantially non-contactengagement, as desired. The turning member can include any operativemechanism, such as knock-down bar, a low grabbing momentary nipapparatus or the like, as well as combinations thereof. In a particularaspect, the turning member can include a curved or otherwise inclinedentry region thereof. In a further aspect, the turning of the selectedarticles can include an engaging of the selected articles with a curvedski member 58. The turning ski can be configured to operativelyknock-down any articles that are standing with their long, firstdimension 32 aligned generally up-and-down, approximately along thelocal vertical direction. As a result, substantially all of the articles28 can be operatively aligned with their longer, first dimension 32extending along the machine-direction 22. The tapered entry region ofthe turning ski can help to provide a gradual, entry transition, and canhelp prevent jams from occurring during the turning operation. Theturning system can also include a bottom catch plate 56, which can beconfigured to help maintain a desired height alignment of the articles,and help prevent the articles from unintentionally leaving theproduction process flow. The turning ski 58 can, for example, becomposed of stainless steel, and can have a composition which includeshardened polymers, aluminum or other type alloys, as well ascombinations thereof.

The article alignment system can include a cooperating second conveyor54, and the second conveyor can be configured to accept articlestransferred from the take-away conveyor 50. In a particular aspect, thesecond conveyor 54 can be configured to transport the articles to and/orfrom the turning system. Any operative transporting mechanism can beemployed to provide the second conveyor 54. For example, the secondconveyor can include a side-by-side nip belt system. The second conveyor54 is desirably configured to run at a second conveyor speed which isoperatively faster than a first conveyor speed provided by the firstconveyor 50. The resulting, differential increase in speed can helpensure that there is a selected spacing distance between successivearticles. The spacing distance can help allow sufficient space/time forpositional changes at the product turning ski, and can help allowadequate space/time for other subsequent operations.

A further feature of the method and apparatus can include a system ofcooperating, counter-rotating, lobed-cam rollers 126, asrepresentatively shown in FIGS. 6 and 6A. The lobed-cams can bepositioned relatively upstream from the selected orienting system (e.g.upstream from the selected system of twist-belts), and may be locatedrelatively upstream from the second conveyor 54. The system oflobed-cams 126 can be configured to provide a desired, spaced-apartsequencing of the articles 28 into the employed orienting system. Asrepresentatively shown, each lobed-cam has a portion with a relativelylarger radius, and a portion with a relatively smaller radius. Thelarger-radius portions of the cooperating cams are configured andcoordinated to form a nip region therebetween which can operativelyengage and move an article 28. The smaller-radius portions of thecooperating cams are configured and coordinated to form a nip regiontherebetween which can substantially avoid engaging and moving anarticle 28. As a result, the system of lobed-cams 126 can engage andmove an article 28 with an intermittent, spaced-apart sequencing.

The operation of the lobed-cams 126 can be coordinated with thetransition time period needed to move an individual article through arotational conveyor (e.g. a set of twist-belts). More particularly, thelobed-cams can rotate once per each desired transition period to assistin the metering of articles into the rotational conveyor system. Thiswill help to insure that each article is metered and delayed until thepreceding article has been successfully transferred to a subsequent,relatively downstream conveyor or other processing operation. Thelobed-cam system can act as both a brake and a sequencer to ensure thatthe rotation conveyors have sufficient time to complete their controlleddelivery of articles, and to complete any needed indexing movement. Itshould be readily appreciated that the rotational speed of thelobed-cams and/or the circumferential extent of the larger-radius, lobedportions of the cams can be appropriately configured to provide thedesired metering operation.

In a further aspect, the method and apparatus can include a mechanism orsystem for identifying appointed end-articles 72 of each article-set 70(e.g. FIG. 8). An additional aspect can include an identifying of apresence of an appointed datum surface 74 (e.g. FIG. 6) with respect toeach end-article 72. Still another aspect can include an identifying ofa desired packaging face-alignment of the datum surfaces 74 of theend-articles 72 of each article-set 70.

The identifying of the desired, packaging face-alignment of the datumsurfaces of the end-articles can include a detecting of a presence of amarker or other predetermined indicator 76 (e.g. FIG. 1). For example,the indicator may be a fold on an outer surface of the article, amaterial-overlap region on the outer surface of the article, packagingmarks on the article, optical markers, magnetic markers, electronicmarkers, electro-magnetic markers or the like, as well as combinationsthereof. In the representatively shown arrangement, for example, theindicator can be a region of adhesive, and the method and apparatus caninclude a detecting the presence of the adhesive. While this aspect ofthe method and apparatus is optional, it may be important where anadhesive buildup may disrupt later processing operations and degradereliability.

The detection of the adhesive or other selected indicator can occurafter the alignment operation, but may alternatively occur prior to thealignment operation. Additionally, the detection of the selectedindicator can be employed in conjunction with an operative controlsystem to determine any rotational adjustments that may be required forparticular articles.

One or more regions of each article may optionally be examined for thepresence of the selected indicator, and the detecting of the presence ofthe predetermined indicator can employ any operative arrangement of oneor more indicator sensors. As representatively shown, each article canbe examined to identify a presence or absence of the indicator and itscorresponding datum surface 74. The examination can occur before orafter the articles have been turned to a consistent, desiredshape-position, and the articles may be examined for an indicator (e.g.adhesive) that is present on only one, major side surface of eacharticle.

In a particular feature, an array of the indicator sensors 60 can beconfigured to detect the position of the indicator on each end-article,such as the position of an adhesive on a major facing surface of eachend-article. In the representatively shown arrangement, for example, theadhesive may include an optical brightener, and the sensor can includeat least one optical sensor 60 that can operatively detect thebrightened adhesive. The optical sensor may, for example, by aluminescence sensor. In a further aspect, the sensor arrangement caninclude a system of two or more luminescence sensors or other indicatorsensors 60.

Based on the positional information provided by the indicator sensor(s),an orienting system can be configured to provide a selectiverepositioning of any end-articles that require an orienting adjustment.The orienting system can thereby provide the desired face-alignment ofthe datum surfaces of the end-articles of the corresponding article-set.In a particular feature, the orienting system can rotate or otherwisemove a selected, out-of-position article to a desired, rearrangeddirectional orientation.

In a desired aspect, the orienting system can be configured to identifyan individual end-article that needs to be rearranged, and toappropriately rotate or otherwise reorient the identified end-article toplace a datum surface (e.g. an adhesive-bearing surface) of theend-article toward an interior or exterior of its corresponding articleset. For example, the adhesive-bearing datum surface of the end-articlecan be processed to have an inward, facing direction, relative to theassociated article-set, and an opposite non-adhesive-bearing surface ofthe end-article can be processed to have a relatively outward, facingdirection.

After the articles have been knocked down or otherwise processed by thealignment system (e.g. turning ski 58), the articles may be transferredto a secondary side-by-side nip conveyor, There can be a gap spacethrough which the articles are handed-off to the secondary conveyor, andthe space can allow a sensor system to detect the selected indicator andidentify the orientation of the datum surface of each article. Forexample, a detection of adhesive can be accomplished by employing asystem of luminescence sensors. In a desired arrangement, three sensors60 can be mounted in the gap space, looking at the top and bottom halfof both sides of the product. While only two sensors are needed, up tofour or more sensors may be employed to provide improved reliability andaccuracy.

After the articles 28 have been knocked-down or otherwise turned, thearticles can optionally be transferred to the orienting system. Anyoperative orienting system may be employed. The orienting system isconfigured to selectively reposition or otherwise rearrange particular,identified articles to a predetermined position. In a particular aspect,the orienting system can be configured to rotate the identified articlesthrough a predetermined amount of angular rotation. The direction of therotation can be determined by the control system based on the detectiondata provided by the indicator sensor arrangement.

With reference to FIGS. 7, 8, 9 and 9A, the orienting system can includea rotational conveyor system with a suitable conveyor drive system. Therotational conveyor system can be configured to provide a selectiverotating or twisting of the selected articles (e.g. the end-articles 72)for which a desired reorientation has been identified. In a particularfeature, the orienting system of the method and apparatus can beconfigured to generate a desired twist motion and displacement byrotating the selected article about a twist axis that is alignedgenerally parallel to the local machine-direction. As representativelyshown, an operative rotating of the identified end-articles can beprovided by a device which includes a twist-belt system, and thetwist-belt system can include at least a first set of cooperatingtwist-belts 66. Additionally, the orienting system may further includeat least a second set of cooperating twist-belts 68.

Each individual set of twist-belts can include at least one cooperatingpair of face-to-face, counter-recirculating belt members that move onassociated belt rollers (e.g. FIG. 7). Optionally, an operational set oftwist-belts can include two or more cooperating pairs of face-to-face,counter-recirculating belt members (e.g. FIG. 8). In their variousconfigurations, each of the pairs of twist-belts can be cooperativelydriven to move at a suitable belt speed. In desired arrangements, thecooperating pairs of twist-belts are operatively driven to moveapproximately equal belt speeds. The counter-recirculating belt memberscan form therebetween an extended nip region that can operatively engageand carry the articles 28 along the method and apparatus. Eachcooperating belt-pair can be configured to impart a desired amount oftranslational and rotational movement to an article that enters andmoves along the local machine-direction through the extending nip regionthat is provided between the pair of face-to-face belts.

With reference to FIG. 7, a first configuration of twist-belts (asrepresentatively shown by the first set of twist-belts 66) can beconfigured to displace and rotate an article in a first twist direction,and a second configuration of twist-belts (as representatively shown bythe second set of twist-belts 68) can be configured to effectivelydisplace and rotate an article in a second twist direction that issubstantially opposite the first twist direction. The first set oftwist-belts 66 can, for example, be configured to rotate or twist anidentified article (e.g. an end-article 72) in a generally clockwisedirection through a twist angle of about 90° (where such angle isdetermined relative to a beginning orientation of the article when thearticle enters into the first set of twist-belts). The second set oftwist-belts 68 can be configured to rotate or twist an identifiedend-article in a generally counter-clockwise direction through a twistangle of about 90°. As illustrated, for example, each set of twist-beltscan be configured to accept an article in a generally standing-upposition, and rotate the article approximately ±90° (plus or minus 90°)to a generally flat-out, output feed position.

In a particular aspect, the selective orienting (e.g. rotating) of theappointed articles (e.g. end-articles 72) can include a selectiveindexing between predetermined sections of the employed, rotationalconveyor system (e.g. between the first and second sets of twist-belts66, 68). To provide the indexing, the method and apparatus of theinvention can include a carriage system, such as a system which includesthe representatively shown shuttle carriage 94 and carriage traversingrails 95. In a particular configuration, the sets of twist-belts (orother rotational conveyors) can be operatively connected and attached toa mounting plate, and the mounting plate can be secured to the shuttlecarriage 94. Where the two sets of twist-belts are configured to provideopposite rotations of the selected end-articles, the carriage can beoperatively indexed to traverse back-and-forth on the carriage rails 95,as needed to provide the desired orientation of the selectedend-article.

The shuttle carriage can selectively operate so that the articles 28 canexit the article alignment system (e.g. such as provided by the systemthat includes the turning ski 58) and enter each section of therotational conveyor system, substantially without changing or divertingfrom the article's original exit path. In a particular feature, theshuttle carriage can be configured to stay in position until therotational conveyor has delivered an individual product to a subsequent,downstream stacker conveyor. When desired, the carriage can move andindex to its other predetermined position to provide a reversed rotationof an identified article.

A braking mechanism, such as provided by a small brake plate, may beemployed at the in-feed entry region of the rotational conveyor systemto allow sufficient time for transitioning between the predeterminedindex positions. This plate can have a flat surface and can extendacross a gap between the sections of the rotational conveyor (e.g. thesets of conveyor twist-belts 66, 68) and the preceding portion orcomponent of the method and apparatus.

With reference to FIGS. 8, 9 and 9A, the selective orienting (e.g.rotating) of the end-articles can alternatively include a selectiveindexing operation conducted with an individual, single set ofcooperating twist-belts 66. To provide the indexing, the method andapparatus of the invention can incorporate a carriage mechanism thatincludes a rotatable indexing wheel 120. The indexing wheel 120 canprovide and have a first position which operatively configures the setof twist belts 66 to rotate an article in a first rotational direction.Additionally, the indexing wheel can provide and have a second positionwhich operatively configures the set of twist belts 66 to rotate anarticle in an opposite, second rotational direction.

The indexing wheel can be supported in a frame 122 and rotatably mountedtherein. In a desired aspect, the indexing wheel can have an axis ofrotation that is aligned generally parallel to the localmachine-direction. The indexing wheel 120 can be operatively driven andactuated to selectively oscillate or otherwise traverse back-and-forththrough a wheel, angular movement which is from about +90 degrees toabout −90 degrees (about ±90°). As a result, the total range of theangular movement of the indexing wheel can be approximately 180 degrees.Any suitable drive mechanism 124 can be operatively connected to actuatethe indexing wheel through the desired amount and direction of movement.For example, the drive mechanism 124 can be configured to operativelyengage a circumferential region of the indexing wheel 120. Additionally,the circumferential region of drive engagement can extend along aperipheral section of the indexing wheel. In particular arrangements,for example, a belt-drive, gear-drive, chain drive, clutch-drive,hydraulic-drive or the like may be configured to operatively engage acircumferential section or other suitable section of the indexing wheel.It should be readily appreciated that other operative driveconfigurations may alternatively be employed, as desired.

The associated twist-belt system 66 is operatively connected to theindexing wheel 120. In a particular configuration, the twist-belt systemcan include a substantially stationary (substantially non-translating)set of rotatable belt rollers 67, and a movable (selectivelytranslating) set of rotatable belt rollers 65. The stationary set ofbelt rollers can desirably be located at an entry region of theorienting system. The movable belt rollers 65 can be operatively mountedon and attached to the indexing wheel 120, and can be arranged tooperatively position the belt nip region along a center region of theindexing wheel. As illustrated, the indexing wheel can include agenerally central, wheel opening which extends through the axialthickness of the indexing wheel. The rollers 65 can be suitably mountedin the wheel opening, and the oriented articles can be passed along thelocal machine-direction and through the wheel opening for furtherprocessing. The illustrated wheel opening has a generally rectilinearshape, but any other operative shape may alternatively be employed, asdesired.

In the representatively shown position of the indexing wheel 120 (e.g.FIG. 8), the indexing wheel and the connected array movable of movablerollers 65 are arranged to impart a counter-clockwise twist to anarticle to thereby turn the article through a counter-clockwise twistangle of about 90°. When desired, the indexing wheel can be selectivelyrepositioned by operatively traversing the wheel through a rotationalangle of about 180° (e.g. clockwise or counter-clockwise, as appropriateto avoid tangling the belt set). Accordingly, the indexing wheel and theconnected array movable of movable rollers 65 can be rearranged toimpart a desired clockwise twist to an article which can thereby turnthe article through a clockwise twist angle of about 90°.

The exit from the employed twist-belt system can be configured to feed athird, stacker conveyor 96, and the third conveyor can include anyoperative mechanism. In the shown arrangement, for example, the thirdconveyor 96 can include a lug-style, paddle chain conveyor system. Thestacker conveyor can alternatively include other known, conventionalconveyor systems and devices.

An operative system of sensors and controls can be employed to regulatethe article directing system, the first conveyor system and the articlealignment system. In the representatively shown arrangement, forexample, a directing slide jam-detect sensor, such as provided by aphoto-eye, can be located at the bottom the directing slide 42, and canbe arranged to observe across the delivery region at the exit end of thedirecting slide. The sensor can detect a jam condition and can bearranged to cause the metering drum to stop moving until the jam iscleared. For example, a blow-off air blast system may be employed tobreak apart and remove the jammed condition.

An electric motor with a variable speed drive can be operativelyconnected to drive the product take-away vacuum conveyor 50. In aparticular arrangement, the drive motor can be located at or near thebottom of the directing slide 42. The take-away conveyor can capture andtransfer each article 28 from the discharge end of the directing slide,and carry each article to the in-feed region the product turningmechanism 58. The variable speed drive can selectively adjust the speedof the conveyor 50 to help optimize the operation of the method andapparatus. A turning system, jam sensor, such as provided by aphoto-eye, can be configured to detect a jammed condition in the turningdevice. The jam sensor can, for example, be located at the pad turningski 58, and arranged to observe across the conveyor 50 along the localcross-direction 24.

An operative system of sensors and controls can also be employed toregulate the article orienting system. In a particular aspect, ametering brake system, such as provided by a mechanism which includes asolenoid with an associated cylinder, can be located at an in-feedregion to the rotation conveyor system. The solenoid can, for example,be employed to assist a geared-in, rotational helper finger. Therotation of the helper finger or kicker can be coordinated with thetransition time period needed to move an individual article through arotational conveyor (e.g. a set of twist-belts). More particularly thehelper finger can rotate once per transition period to assist in themetering of articles into the rotational conveyor system. This will helpto insure that each article is metered and delayed until the precedingarticle has been successfully transferred to the stacker conveyor 96.The kicker, metering system can act as both a brake and a sequencer toensure that the rotation conveyors have sufficient time to completetheir controlled delivery of articles.

A rotational conveyor servo motor can be mounted to a rotation conveyordrive frame, and can be operatively connected to control the speed ofthe rotation conveyors (e.g. the twist-belts 66, 68). Additionally, acarriage actuator can be operatively connected to the mechanism thatswitches and transitions the shuttle carriage 94 between its appointedindex positions. The carriage actuator may be any operative activationdevice, and may include any operative activation device set forth in thepresent disclosure. For example, the activation device can be providedby a shuttle drive motor.

A positive-over-travel proximity switch can be located on the indexingcarriage system (e.g. shuttle carriage 94, or indexing wheel 120) toprotect against equipment damage. Similarly, a negative-over-travelproximity switch can be located on the carriage system to protectagainst equipment damage. A home proximity switch can be located on thecarriage system to provide a set reference for the carriage mechanism.

A stacker registration in-feed sensor 64, such as provided by aphoto-eye, can be located on the rotational conveyor system (e.g.twist-belts 66) to detect a registered input position of an articlebeing delivered to the stacker conveyor 96. The in-feed sensor 64 candetect and help move the stacker conveyor to dynamically captureincoming articles at predetermined locations in the stacker conveyor. Ifthe rotational conveyor system includes more than one set oftwist-belts, additional in-feed sensors may be employed, as desired.

An article rotation, jam detect sensor, such as provided by a photo-eye,can be located at exit region of the rotational conveyor system. Thissensor can be configured to detect a jam condition that may occur at theregion between the exit from the rotational conveyor system and thein-feed to the stacker conveyor 96.

A stacker-not-ready, diverter system can be located at the in-feed tostacker conveyor. The diverter system may include a pneumatic blow-offmechanism positioned proximate the exit of rotational conveyor system.The diverter system can operatively remove or blow-off any incomingarticles that would require a movement of the stacker when the stackeris not in a safe condition for movement. The diverter system can also beconfigured to work in cooperation with the exit jam detect photo-eyethat is proximate the in-feed to the stacker conveyor 96.

An arrangement of indicator sensors 60 can be located before the in-feedto the rotational conveyor system. In a particular feature, the sensorarrangement can, for example, be located proximate a small space that ispresent between the hand-off from the second conveyor 54 to a subsequentorienting system. The sensor arrangement can be mounted in this gapspace, and can be configured to look at the top and bottom half of bothsides of the product. Only two sensors are needed, although up to foursensors may be used. The detected presence of adhesive provides data asto how the article is oriented. The control system can be configured touse this data and determine which direction, if any, the productrotation conveyors should rotate to properly deliver the product. Forexample, the article may be a pouch having a folded and adhered section.The indicator sensor (e.g. adhesive sensor) can look for the position ofthe fold and help the process control system adjust and select theconfiguration of the rotational conveyors needed to provide a desired,packaging face-alignment of the articles 28.

The method and apparatus can further include a system for arranging ofthe articles 28 into a desired stacking configuration. At least onearticle-set 70 can be identified and accumulated, and a formedarticle-set can contain a selected number of the articles 28.Additionally, the selected number of articles can be arranged into astack or other arrayed configuration suitable for packaging.

A stacking section of the method and apparatus can employ any operativestacking technology. As representatively shown in FIGS. 9 through 11C,the stacking system can receive articles from the rotational conveyorsystem (e.g. twist-belts 66, 68) and can transport the articles to asubsequent package or bag loading section. When sufficient articles fora predetermined row or other article-set are delivered to a dischargeregion of the stacker system, the article-set can be moved to a transferpusher staging section. The staging section can include a pushermechanism 98, such as provided by an overhead pusher, can move thestacked articles out of the stacker, conveyor 96 and into an automaticpackaging or bagger loader section of the manufacturing process.

In a particular aspect, the stacker conveyor 96 can be arranged toreceive the articles 28 in a laid-down, generally flat orientation, andto transport the articles to the entry region of the transfer pushermechanism 98. In another feature, the conveyor 96 can be constructed toinclude a holding mechanism, such as provided by lugs, fingers, paddles,buckets or the like. As representatively shown, the method and apparatusmay include a system of one or more paddles or fingers 112 which canaccept an individual article with a generally flat transfer area. Such atransfer area can allow the individual article to be smoothlytransferred into and out of the fingers. A selected “pitch” spacing canalso be incorporated between the articles 28 to allow a non-capturedtake-up on the return path of the conveyor 96. This arrangement can helpimprove the adaptability and efficiency of the method and apparatus.

The stacker conveyor 96 can be controlled in a well known, conventionalmanner that is based upon the speed of the in-feed conveyor (e.g.twist-belts 66, 68), coupled with a sensor which detects the presenceand position of an incoming article relative to the in-feed conveyorspeed. When an article is detected, the drive system can advance thestacking conveyor 96 by a predetermined increment to receive thearticle, and then advance the conveyor 96 an additional increment foreach successive article that is detected.

In a desired configuration, the stacker conveyor 96 can be arranged toprovide a stacker speed that is at least a minimum of about 30 articlesper minute. In a particular feature, the stacker speed can be up to amaximum of 100 articles per minute, or more. Other features can includea stacker speed within the range of about 50-100 articles per minute.

To provide a more portable and efficient design, the stacking conveyorcan be configured to substantially avoid an undesired “capture” thefinal packaging machinery or other downstream equipment. As a result,the stacking conveyor can substantially avoid an undesired encircling orsurrounding of a substantially fixed portion of the cooperatingdownstream equipment (e.g. packaging machinery) that has beensubstantially permanently installed. Accordingly, the stacking conveyorshould not need an excessive amount of disassembly or separating-apartto move the method and apparatus of the invention to another,alternative location. The final packaging or bagging equipment can bestationary and substantially permanently mounted, while the accumulationsystem and associated stacking device of the invention can be relativelymobile and portable. Such a configuration can allow a more flexible andmore efficient utilization of the method and apparatus of the invention.Additionally, the stacking conveyor 96 can be configured to remain in asubstantially stopped condition whenever it is determined that amovement of the stacking conveyor would interfere with the operation ofthe overhead product transfer pusher 98.

To help avoid a capturing of the subsequent, downstream equipment, thestacking conveyor 96 can be configured to have a distinctive“goose-neck” or “elbow” configuration, as representatively shown inFIGS. 9 through 10A. The exit or discharge portion of the conveyor canhave a cantilevered configuration which can extend over and across amachine-direction of the cooperating downstream equipment. Asillustrated, the stacking conveyor can include a turning mechanism whichhelps form the elbow configuration. In a particular feature, the turningmechanism can include a first turn roller system 128 and a second turnroller system 130. The first turn roller system 128 may include at leastone and desirably a plurality of individual rollers, and can beconfigured to operatively engage at least an appointed bottom-sideportion of the conveyor 96. The second turn roller system 130 mayinclude at least one and desirably a plurality of individual rollers,and can be configured to operatively engage at least a portion of anappointed article-side of the conveyor 96, which is opposite thebottom-side portion.

In the example of the shown arrangement, the second roller system 130can include at least one cooperating pair of rollers, which can beaxially spaced apart along the local cross-direction 24. Each roller ofa roller-pair can operatively engage a corresponding side edge region ofthe stacking conveyor 96. For example, a timing chain may be attached toeach side region of the stacking conveyor, and the rollers of the secondroller system 130 can include gear-teeth that cooperatively engage withtheir corresponding timing chain.

The second roller system 130 is configured to allow a substantiallyunimpeded movement of any holding members or other conveyor members(e.g. paddle members 112) that may extend away from the article-sidesurface of the stacking conveyor. For example, the rollers of the secondroller system 130 may have a relatively large diameter such that an axleshaft of the second roller system 130 is sufficiently spaced away fromthe article-side surface of the stacking conveyor to operatively avoidthe paddle members 112 or any other members that project away from thearticle-side surface of the stacking conveyor. Other avoidancearrangements may also be employed, as desired. For example, each of theaxially-spaced rollers 130 can be mounted on a separate axle that extendlaterally away from the holding members and do not extend into the areabetween the rollers that is traversed by the holding members.

With reference to FIGS. 10 through 11C, a transfer, loading system ofthe method and apparatus can include a transfer pusher mechanism and apackage loading mechanism. As representatively shown, a transfer pusher98 can operatively transfer completed rows or other article-sets 70 ofproduct from the stacking conveyor 96 to a subsequent, downstreampackage loading device 100. As representatively shown, the transfermechanism 98 can include an overhead pusher carriage 114 and a pusherbar mechanism 102, and may further include a conventional finger assistmechanism that includes finger members that extend into the regionbetween individual conveyor paddles 112 to engage the conveyed articles28. The overhead pusher carriage can include a side-by-side drive whichallows an overhead, circular rotation to convey the pusher bar. Theoverhead drive arrangement on the pusher carriage can be configured toreturn to a ready position without interfering with any article ormachine component.

The control system of the method and apparatus can be configured in aconventional manner such that when a completed article-set 70 of productis ready for transfer, the pusher bar 102 will index forward from aready position and push, pull or otherwise transfer the articles out ofthe stacking conveyor 96 and toward a storage buffer mechanism, such asprovided by the illustrated staging plate member 104. The pusher bar 102can be at least as long as a completed row of product and short enoughto fit between optional side guide rails that can be located at anentrance into the staging plate area.

The finger assist mechanism (not shown) can be setup to fit betweenpaddle members 112 of the stacking conveyor 96. This arrangement canallow a pushing action on the articles at location that is below itscenter of gravity, and can improve the consistency of the handoff fromthe conveyor 96.

The staging plate 104 provides an area upon which to stage at least onearticle-set 70 of product in the event that the package-loading deviceis not immediately able to accept the article-set. The staging plate canprovide a substantially flat, smooth surface, and can include adjustableside rails 110. This arrangement can provide a storage buffer mechanismwhich assists a substantially continuous operation of the stackingconveyor 96, and can provide additional time to unload a desiredplurality of article-sets into the packaging equipment. For example, acomplete grouping of article-sets 70 (e.g. FIG. 1B) may include amultiplicity of two or more article-sets 70. The product articles mayneed to be staged until the desired number of rows or other article-setshave been gathered and are ready for online loading into the desiredpackaging configuration. The staging area can accept the required numberof rows until the method and apparatus are ready to load them into thedesired packaging. Various transfer pusher mechanisms are available fromcommercial vendors. For example, suitable mechanisms are available fromOptima-Maschinenfabrik, Dr. Buhler GmbH & Co., a business having anaddress at Steinbeisweg 20, D-74523 Schwabish Hall, Germany

Conventional sensors and controls can be employed to regulate thearticle stacking systems. In the representatively shown arrangement, forexample, a stacking conveyor servo motor can be located on a drive pointof the stacking conveyor 96 to operatively drive the stacker chain in aregistered manner that is coordinated with a registration sensor locatedin the rotation conveyor system (e.g. twist-belts 66, 68).

A stacking conveyor home/registration detect sensor, such as provided bya photo-eye, can be configured to observe across at a finger on thestacker conveyor. The sensor can help sequence a “home” position on aonce per product or on a product-to-product basis. This home positioncan be employed to provide a positional zero reference registrationpoint, and can provide a starting reference point for a selected,electronically driven mechanical motion.

An article-counting sensor 78 (e.g. FIG. 9), such as provided by aphoto-eye, can be located just upstream, before the transfer sectionfrom the stacker conveyor 96. The counting sensor 78 can help verifythat a complete article-set is present for transfer. If an article-setis incomplete, the stacker conveyor 96 can be indexed further to presenta next available article-set.

An overhead pusher transfer servo motor can be configured to drive theoverhead stack transfer pusher 98 to convey articles from the stackerconveyor 96 into the package loader mechanism 100. An overhead pusherhome switch, such as provided by a proximity switch, can be located onthe overhead transfer pusher 98 to provide a home position reference forthe overhead pusher device. An “article-present” sensor 79 (e.g. FIG.9A), such as provided by a photo-eye, can be located along the path ofthe stacker conveyor 96 after the location of the transfer pushermechanism 98. The sensor 79 can detect any residual, non-transferredarticles that are to be culled from the stacker conveyor 96. A finalcull device, such as provided by a blow-off cull solenoid valve, can belocated relatively downstream from the transfer pusher section andpositioned operatively proximate the article-present photo-eye. The culldevice can be configured to remove any un-transferred articles thatremain in the stacker conveyor. In an alternative arrangement, themethod and apparatus may be configured to have gravity remove theresidual articles in the culling operations.

As representatively shown in FIGS. 7 through 9A, an article, rotationcontrol system can be configured to alter the orientation of anend-article 72 of a particular article-set 70, depending on the locationof the selected indicator (e.g. adhesive) relative to the desired finalorientation of the end-article when the end article is discharged fromthe stacker conveyor 96. The components of the rotation control systemcan include: a computer (e.g. an ALLEN-BRADLEY brand, 1756-L1CONTROLLOGIX Programmable Logic Controller computer, and an ALLENBRADLEY brand, 1394 Servo Controller computer which is available fromRockwell Automation, a business having offices located in Milwaukee,Wis.). Additionally, the control system can incorporate associatedcomputer software and software know-how, which are also available fromRockwell Automation.

The stacker conveyor 96 can include an array of individual, articlecarriers, such as carrier slots or buckets. The article carriers aredesirably, substantially regularly spaced along the length of thestacker conveyor, and typically will hold only one article. Thisattribute can be of particular assistance in the operation of theorienting, rotation control system.

Each article-set 70 can, for example, have a certain number of articlesper “row”. The control system will be programmed to know the number ofarticles per row and utilize it to decide whether or not a particularend-article needs an adjusted orientation or rotation. Upon an initialsystem startup, the stacker conveyor 96 will synchronize itself by wayof the servo control of the stacker conveyor, and will align itself ontoone of the stacker conveyor “buckets”. This system alignment willrepresent the system count reference position.

On each row of product, the first and last article of the row wouldrepresent the end-articles that are to be particularly examined todetermine whether or not an adjusting rotation is desired. For example,the method and apparatus may be configured to align the end-articlessuch that the flap-member of the article is either (a) facing inwardlytoward the rest of the current row, or (b) aligned such that a movementof the article across a friction-producing surface would keep theflap-member closed and not undesirably open or expose adhesive. In aparticular configuration of the invention, there can be four possibleorientations of the pouch and three out of four will normally beacceptable from an orientation standpoint. The control system of thepresent invention can advantageously detect the actual orientation ofthe identified end-article, and compare it to the acceptableorientations of the end-article. If a predicted-orientation of aparticular end-article differs from all of the acceptable-orientations,the rotation conveyor system can be appropriately shifted to a differentarrangement prior to moving that particular end-article into therotational conveyor system (e.g. twist-belts 66, 68).

A first aspect of this operational task is to identify the location ofthe end-articles (e.g. the first and last articles in a product row)with respect to the entry of the stacker conveyor 96. This can beaccomplished by manually inputting each desired packaging or bagconfiguration into the computer software. For example, if the bagconfiguration has a row, article count of 10, then the software wouldcount the number of articles from our reference position to the entry ofthe stacker. This count can be computed into the following formula bylooking at the remainder of the following division formula:(Buckets from Entry to Reference}/(Product Row Count)=>Value plusremainder

A software-initiated counter would count to the number of articles ineach row, and would count from one to the selected top number. Thecounter would reset when the top number would be reached. The countingis performed each time the stacking conveyor accepts a new article andindexes to its next position to accept the next new article. Thisoperation can create the following, recurring sequence:

-   -   Example: Row Count=10    -   1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 1,        2, . . .

Based on this sequence range and the remainder-value of the previousdivision calculation, the computer can determine which articles need tobe identified for reorientation or rotation. The remainder-value wouldrepresent the first product to be examined and can represent anappointed “outside” article, which is the article which will come incontact with a side guide mechanism positioned on a relatively far,first side of an operative packaging or bagger device. The desiredorientation for this end-article is such that the end-article is facinginward, toward the rest of the row stack, or turned such that the “openedge” of the flap-member is directed downstream, opposite to thedirection flow of the packaging or bagger system. This desired resultcan be designated as “A”.

An appointed “inside” article, or article which comes into contact witha side guide mechanism on a relatively near, second side of the selectedpackaging or bagger equipment, can be determined by subtracting “one”article from the remainder-value number. If there is no remainder-value,then the “one” value should be subtracted from the Row Count. If theremainder is one then the value will be the value of the Row Count (e.g.10). One can identify this result as “B”. The article's desiredorientation is to be such that it is facing inward toward the rest ofthe row stack, or turned such that the “open edge” of the flap-member isdirected downstream, opposite to the direction flow of the packaging orbagger system.

Results A and B will be used to compare to the recirculating counter,which counts from “1” up to the selected Row Count (e.g. 1-10). When thecounter value equals either A or B it will be compared to the predictedorientation, and may or may adjust the rotation conveyor system to adifferent index position, based on the feedback data from the indicator(e.g. adhesive) detection system.

The indicator detection can, for example, arise from data generated fromthe adhesive detecting, luminescence sensors. An array of three sensorscan be employed to help minimize the amount of indexing needed by therotation conveyor system. After an article has been processed by theturning member 58, the indicator sensors 60 can, for example, be mountedto look at the top and bottom edge regions of one major facing-surfaceon one side of the article, and to look at a region on an opposite,major facing-surface of the article. Each article can be examined in aconveyor drive gap between belt rollers where a gap or spacing betweenarticles will be created due to speed differential between theconveyors. There may be a small buffer area between sensing operationand the entry to the rotational conveyor system. Photo-eyes can detectand count articles moving in and out relative to the reference in-feedpoint to ensure that a proper pad orientation is being examined.

An automatic bagger or package loader mechanism 100 can be employed todetermine a spare, operational opening in the packaging or baggerin-feed, and to load a complete article-set of product into the runningbagger. The packaging loading device or mechanism 100 of the method andapparatus can take one or more article-sets of product and automaticallyload them into the final packaging machinery (e.g. FIGS. 11 through11C). Accordingly, the method and apparatus of the invention can move atleast one appointed article-set 70, and optionally a plurality of thearticle-sets into a corresponding package.

The package loading device or mechanism 100 can include a bottom trapdoor system 116, end rails and side rails 110, and a pusher device. In aparticular feature, the mechanism can include an overhead, vacuum pusherdevice. As representatively shown, the loading device 100 can acceptarticle-sets 70 of product at its in-feed. The bottom trap door portionof the loading device can be configured to move to an open-position suchthat the open trap door members (e.g. door plates 116) can become flushwith the package being loaded while substantially avoiding anymechanical conflict with a cooperating packaging conveying system. Thedoor members can be operatively controlled by various well known,conventional mechanisms. For example, the door plates 116 can becontrolled by a mechanism or system which includes a mechanicalrotational cylinder. The control system of the method and apparatus canbe configured to open just prior to a loading operation conducted by thepackaging system, and to close when the loader device 100 is receivingarticle-sets of product from the product transfer pusher 98.

The overhead vacuum pusher device can include a vacuum box 108 and avacuum conduit 109 which is operatively connected to the vacuum box.Additionally, a pusher-device actuator, such as provided by pneumaticactuator cylinders 107, can be attached to move the vacuum box todesired predetermined pusher-positions. In a particular feature, thevacuum pusher device can be operatively positioned over and verticallyabove the completed article-set of product appointed for packaging, andcan employ a vacuum force to operatively engage the article-set. Thevacuum is operatively configured to make a positive connection with theappointed article-set, and help hold the articles in a positionappropriate for loading into the final packaging equipment. In a desiredfeature, the overhead vacuum pusher system can be configured to maintainthe array of articles and vacuum-hold the articles against the vacuumbox 108 in a substantially fully-suspended position. The actuator can beoperated to extend and operatively move the vacuum box 108 andassociated articles to a desired packaging position. Additionally, themethod and apparatus can be configured to release the vacuum as soon asthe articles have been suitably transferred or otherwise moved into thedownstream, final packaging machinery. After the articles have beenreleased, the actuator can be operated to retract and return the vacuumbox to an initial position suitable for receiving and holding a newgrouping of articles 28.

Accordingly, the transfer pusher mechanism 98 can index and position anarticle-set into the appointed staging area (e.g. as provided by astructure which includes staging plate 104). When sufficient rows orother article-sets are present and when a spare opening is detected inthe bagger, a top pusher mechanism of the package loader 100 can pressdown while bottom plates of the package loader are opened. The toppusher can include a vacuum source which can help hold the appointedarticle-set as the bottom trap-door is opened. This system can thenreturn to a ready-position after each loading operation. The stagingdead-plate 104 can be mounted between the packaging loader and thestacker finger area to stage a row of pads while a loading operation isoccurring.

Conventional sensors and controls can be employed to regulate thearticle packaging or bagging systems. A trap-door-closed sensor, such asprovided by a proximity switch, can be employed to monitor each of thetrap doors of the loading mechanism 100. Each trap door may, forexample, be operated by a rotational trap door cylinder, and eachrotational cylinder can be configured with a proximity switch to verifythat the trap door is closed. Similarly, a trap-door-open sensor, suchas provided by a proximity switch, can be employed to further monitoreach of the trap doors of the loading mechanism 100. Each trap door may,for example, be operated by a rotational trap door cylinder, and eachrotational cylinder can be configured with a proximity switch to verifythat the trap door is open.

A packaging loader, vacuum-pusher-retracted sensor, such as provided bya proximity switch, can be located on an actuator device of the loadingmechanism 100 to verify that the load pusher is fully up and ready toaccept new product. The actuator may, for example, include a pneumaticactuating cylinder.

An overhead loader, vacuum-pusher-at-prestage sensor, such as providedby a proximity switch, can be located on the actuator device to verifythat the load pusher member is at an appointed prestage position, and isready to drop to a discharge height. Additionally, a packaging loader,vacuum-pusher-at-discharge sensor, such as provided by a proximityswitch, can be located on the actuating cylinder to verify that the loadpusher is at a predetermined discharge position, and is ready to releasevacuum to drop the articles.

An overhead pusher, loader-extend mechanism, such as a device thatincludes a solenoid valve, can be employed to control the loader,actuating cylinder. The valve can operatively control a desiredextension of the overhead portion of the loader pusher. An overheadpusher, loader-retract mechanism, such as a device which includes asolenoid valve, can be employed to further control the loader-actuatingcylinder. The valve can operatively control a desired retraction of theoverhead portion of the loader pusher.

A vacuum sensor can be employed to detect vacuum present on packagingloader 100, and can be located on the overhead pusher loader mechanism.The vacuum sensor can be configured to detect a positive vacuum presenceprior to allowing the trap doors to open for loading. Additionally, avacuum enable mechanism, such as provided by a device which includes asolenoid valve, can used to control the vacuum delivered to a vacuum boxin the overhead pusher of the packaging loader 100.

Conventional vacuum generator systems can provide the vacuum needs ofthe method and apparatus. For example, the vacuum system can provide anoperative vacuum to the vacuum take-away conveyor 96 and the packagingloader 100.

Various transporting or conveying devices may be employed to move thetarget work material (e.g. the articles 28) through and between thevarious operations provided by the method and apparatus, and anyoperative transport or conveyor mechanism may be employed. Suchtransport or conveying devices can, for example, be provided bytransport rollers, conveyor belts, pneumatic conveyors, vacuumconveyors, electromagnetic conveyors, fin style conveyors, pushingmechanisms or the like, as well as combinations thereof.

In the various attachments and securements employed in the constructionsof the method and apparatus of the invention, it should be readilyapparent that any conventional attachment or securement technique may beemployed. Such techniques may, for example, include adhesives, welds,screws, bolts, rivets, pins, latches, clamps or the like, as well ascombinations thereof.

Similarly, it should be readily apparent that any conventional materialmay be employed to construct the various components incorporated intothe method and apparatus of the invention. Such materials can includesynthetic polymers, fiberglass-resin composites, carbon fiber-resincomposites, metallic composites, ceramic composites, and the like, aswell as combinations thereof. The materials are typically selected toprovide desired levels of strength, durability, ease of manufacture, andease of maintenance.

The method and apparatus of the invention can occupy a relatively smallamount of floor space and can be highly portable. The method andapparatus can, for example, be setup to allow relatively easy movementamongst manufacturing machines, and to allow a quick setup by plugginginto electric and pneumatic power sources. The method and apparatus canbe mounted onto rollable wheels, and can be selectively anchored inplace with set pins.

The method and apparatus can provide automatic jam disruption, and canblow-off or cull any additional product at the stacking conveyorin-feed, if a change to a stopped or paused state is needed. Thisfunctionality can be accomplished by employing air-blast devices. Forexample, the air-blast devices can be located at the bottom of thedirecting slide 42 and at the in-feed to the stacking conveyor system96. The air-blasts can be triggered through jam-detection, photoelectricsensors that provide data to the computer control system.

Distinctive buffers can be incorporated to substantially eliminate aneed to stop or stall due to a lack of articles or due to timing issueswhen operating at normal, designed running speeds. For example, themetering drum 40 can provide a buffer point. When the feed hopper 26 hasemptied its contents into the metering drum 40, sufficient product is inthe metering drum to allow time for the hopper to be refilled and toresume product flow into the drum. Continuous product flow can also beassisted by using the air blast at the in-feed to the stacking conveyor96. If timing considerations are such that the stacker conveyor 96 isunable to advance to accept the next article, the air-blast can cull thearticle to keep the system in a running state. Additionally, thedead-plate 104 between the transfer pusher 98 and the packaging loader100 can help provide a desired, continuous operation. Further, theoverhead attribute of the product transfer device, allows rows ofarticles to be transferred in a continuous operation without making thestacker conveyor 96 wait for a return of the transfer pusher 98.

Although various illustrative and representative configurations havebeen described in detail herein, it is to be appreciated that othervariants, modifications and arrangements are possible. All of suchvariations, modifications and arrangements are to be considered as beingwithin the scope of the present invention.

1. A method for accumulating articles, said method comprising: aninputting of a plurality of individual articles from an article supplysource, each article having at least a first major facing surface, afirst article dimension extending along a first article direction, asecond article dimension extending along a second article directionwhich differs from said first article direction, and an article edgeregion; a directing of each article to a first conveyor; an aligning ofsaid first article dimension of each article along a selectedmachine-direction; an identifying of an article-set which contains aselected, predetermined number of said articles; a forming of at leastone article-set which contains said selected number articles arranged ina configuration suitable for packaging; and a moving of said article-setinto a package; wherein said inputting of said articles includes adispensing of said articles with a rotating, metering drum.
 2. A methodas recited in claim 1 wherein said inputting of said articles includes adelivering of said articles onto a guide surface.
 3. A method as recitedin claim 2, wherein said delivering of said articles includes a layingof said articles onto an inclined slide surface.
 4. A method as recitedin claim 2 wherein said delivering of said articles includes aregulating of said articles with a guide member.
 5. A method foraccumulating articles, said method comprising: an inputting of aplurality of individual articles from an article supply source, eacharticle having at least a first major facing surface, a first articledimension extending along a first article direction, a second articledimension extending along a second article direction which differs fromsaid first article direction, and an article edge region; a directing ofeach article to a first conveyor wherein said directing of each articleto the first conveyor includes a regulating of said articles with asubstantially curvilinear guide members; an aligning of said firstarticle dimension of each article along a selected machine-direction; anidentifying of an article-set which contains a selected, predeterminednumber of said articles; a forming of at least one article-set whichcontains said selected number articles arranged in a configurationsuitable for packaging; and a moving of said article-set into a package.6. A method as recited in claim 5, wherein said guide member is formedto incorporate a funnel curve.
 7. A method as recited in claim 5,wherein said guide member is provided by a fence member that extendsaway from said slide surface.
 8. A method as recited in claim 1, furtherincluding an arranging of said first conveyor to engage said articlesalong their respective article edge regions.
 9. A method foraccumulating articles, said method comprising: an inputting of aplurality of individual articles from an article supply source, eacharticle having at least a first major facing surface, a first articledimension extending along a first article direction, a second articledimension extending along a second article direction which differs fromsaid first article direction, and an article edge region; a directing ofeach article to a first conveyor; an aligning of paid first articledimension of each article along a selected machine-direction; anidentifying of an article-set which contains a selected, predeterminednumber of said articles; a forming of at least one article-set whichcontains said selected number articles arranged in a configurationsuitable for packaging; and a moving of said article-set into a package;wherein said aligning of said article first dimension includes a turningof selected article with a turning member to thereby arrange saidselected article to operatively align said article first dimension ofsaid selected articles along said machine-direction; and said turning ofsaid selected articles includes an engaging of the selected articleswith a curved ski member.
 10. A method for accumulating articles, saidmethod comprising: an inputting of a plurality of individual articlesfrom an article supply source, each article having at least a firstmajor facing surface, a first article dimension extending along a firstarticle direction, a second article dimension extending along a secondarticle direction which differs from said first article direction, andan article edge region; a directing of each article to a first conveyor;an aligning of said first article dimension of each article along aselected machine-direction; an identifying of an article-set whichcontains a selected, predetermined number of said articles; anidentifying of appointed end-articles of said article-set; anidentifying of a presence of an appointed datum surface with respect toeach end-article; a forming of at least one article-set, which containssaid selected number articles arranged in a configuration suitable forpackaging; and a moving of said article-set into a package.
 11. A methodas recited in claim 10, further including an identifying of a desiredpackaging face-alignment of the datum surfaces of the end-articles ofsaid article-set.
 12. A method as recited in claim 11, wherein saididentifying of a desired packaging face-alignment of the datum surfacesof the end-articles of said article-set includes a detecting of apresence of a predetermined indicator.
 13. A method as recited in claim12, wherein said detecting of said presence of the predeterminedindicator includes detecting a presence of an adhesive.
 14. A method asrecited in claim 11, further including a selective orienting ofend-articles that require an orienting adjustment, to thereby providesaid desired face-alignment of the datum surfaces of the end-articles ofsaid article-set.
 15. A method as recited in claim 14, wherein saidselective orienting of said end-articles includes a rotating of saidend-articles with a twist-belt system.
 16. A method as recited in claim14, wherein said selective orienting of said end-articles includes arotating of such end-articles with a twist-belt system that includes afirst set of cooperating twist-belts and at least a second set ofcooperating twist-belts; said first set of twist-belts are configured torotate an article in a first rotational direction; and said second setof twist-belts are configured to rotate an article in a secondrotational direction that is opposite said first rotational direction.17. A method as recited in claim 14, wherein said selective orienting ofsaid end-articles includes a rotating of such end-articles with atwist-belt system that includes a first set of cooperating twist-beltsand an indexing wheel; said indexing wheel having a first position whichconfigures said first set of twist belts to rotate an article in a firstrotational direction; and a second position which configures said firstset of twist belts to rotate an article in an opposite, secondrotational direction.